Overmolding buckles at the same time as overmolding a lens respirator

ABSTRACT

A respirator mask and a method of making the respirator mask that includes a lens member and a plurality of buckle members spaced around the lens member. A flange member is overmolded to the lens member and to the spaced buckle members at the same time by the following method. A mold member is provided to have individual mold supports to individually receive and support the lens member and to individually receive and support the buckle members at the spaced positions around the lens member. The mold member forms a flange cavity around the lens member and extending to the buckle members. The lens member is positioned within its individual mold support and the buckle members are positioned within their individual mold supports at the spaced positions around the lens member. The molding material is then injected into the flange cavity to form a flange that overmolds to the lens member while at the same time overmolds to the buckle members to form the respirator mask.

This Divisional Application is based on U.S. application Ser. No.12/925,446 filed on Oct. 21, 2010 which in turn is based on U.S.Provisional Application #61/280,063 filed on Oct. 29, 2009 by Eric P.Rose for Overmolding Buckles At The Same Time As Overmolding LensRespirator.

BACKGROUND OF THE INVENTION

This invention is in the field of respirators used for personalprotection. Respirators require an attachment means which allow therespirator to be affixed securely to the user's face. In most reusablerespirators, this attachment means is accomplished through the use of aplurality of buckles which connect the mask body to a harness. Thesebuckles typically have an adjustments means which allows a user toadjust the fit of the mask body to the face as needed depending on thesize and shape of their face. Respirator manufactures have used severaltechniques of inserting buckles into a respirator. Most often this isachieved by means of a rivet that extends through a tab on a mask'sflange and simultaneously through a buckle. Secondarily, a separateharness may be strung through the buckle allowing for an adjustmentmeans of securing the mask to the face. This joint assembly of flangetab, rivet, buckle, and harness may be repeated a plurality of times onthe mask as desired by the manufacturer.

The common method of attaching a mask body to a harness through thesystem of rivet and buckle as noted above has numerous shortcomings.Market research has shown, and one skilled in the art would understandthat, over time and with repeated use the rivet joint will loosen up andis likely to come apart. During use of the respirator, typically inhazardous environments, such loosening or unintended disassembly couldpossibly be hazardous to the user's health. From a load distributionperspective in this joint, the typically small rivets and thecorresponding hole they require in the flange's tab offer relativelylittle surface area to carry the load in the joint. With such atraditional multipart assembly, significant costs would be incurred toproduce and assemble the individual parts. This manufacturing costresults in a higher cost of the respirator to the user which may limitthe availability of the product. Also with such a multipart assembly,the product is big, bulky and obtrusive and less aestheticallyappealing.

SUMMARY OF INVENTION

The invention described herein is novel for several reasons and is asignificant improvement over prior art. This invention is one where thebuckles used to attach the mask body to the harness are integrallymolded to the flange's tabs at the same time as the flange itself ismolded to the respirator's lens. The molding of the flange to the lensis part of a prior patent application Ser. No. 12/284,133 filed Sep. 18,2008 and is assigned to the same assignee as the instant application.The flange would generally be injection molded and the molding materialmay be thermoplastic rubber but other materials such as silicone or evencompression-molded rubber, or the like could be used.

This invention is novel and an improvement over prior art and the priorapplication referenced above for several reasons. First, because thereis no rivet in the assembly there is no chance of such a joint looseningover time and extended use. Second, the invention uses a broad surfacearea between the flange tabs and the buckle portions so as to insure afirm connection. The buckle portions may also include openings extendingthrough the buckle portions so that the molding of the flange tabs alsomay be through the openings to further secure the connection between theflange tabs and the buckle portions.

The present invention is simpler in construction, simpler inmanufacturing and lower in cost due to fewer parts and less handassembly than the prior art devices.

A clearer understanding of the invention will be had with reference tothe following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the component parts of the respirator to be assembledduring the molding of the flange,

FIG. 2 illustrates the component parts of the respirator assembled bythe molding of the flange,

FIG. 3 illustrates the component parts of the respirator positioned in atwo-piece mold, and

FIG. 4 illustrates the assembled parts of the respiration positioned inthe mold after molding the flange.

DETAILED DESCRIPTION OF THE DRAWINGS

As illustrated in FIG. 1, the component parts of the respirator includea lens 10, two upper buckle portions 12 and two lower buckle portions14. As can be seen in FIG. 1 both upper and lower portions 12 and 14include openings there through 16 which assists during the molding of aflange member interconnecting the lens 10 and the buckle portions 12 and14.

FIG. 2 illustrates a completed respirator after molding flange.Specifically as shown in FIG. 2 a flange member 18 is overmolded to thelens 10 and the buckle portions 12 and 14. The overmolding of the flangeto the lens 10 is fully described in the previously referenced patentapplication assigned to the same Assignee as the instant application.The overmolding of the flange is accomplished with tab portions 20extending from the flange 12 and with these tab portions encapsulatingthe upper and lower flange members in the area of these flange membersthat include the openings 16. The mold material will flow through theopenings to lock the buckle portions in position. In addition, the tabportions 20 overlay part of the upper and lower buckle portions over abroad area to also ensure a secure engagement between the tab portions20 and the buckle portions 12 and 14.

FIG. 3 illustrates the same components parts shown in FIG. 2 butpositioned within a two-piece mold member 22. As can be seen thetwo-piece mold member has a mold cavity 24 in dotted line which is thesame shape as the flange member 18 shown in FIG. 2. Injection ports 26extend through the two-piece mold 22 and with an injection moldingequipment 28 attached to the ports for injection molding thermoplasticmaterial into the mold cavity 24.

FIG. 4 illustrates the assembled respirator located within the two-piece22 and as shown by arrows 30 the mold may be split along the directionof the arrows 30 so that the assembled respirator can be released fromthe mold. It will be appreciated that other component members can thenbe attached to the assembled respirator including harness membersattached to the buckle portions and other accessories attached to thelens for completion of a full face respirator.

It will be appreciated that other variations and modifications may bemade to the invention as described without deviating from the spirit ofthe invention as described above.

I claim:
 1. A method of manufacturing a respirator mask including thefollowing steps, providing a lens member, providing a plurality ofbuckle members, providing a mold member having individual mold supportsto individually receive and support the lens member and to individuallyreceive and support the buckle members at spaced positions around thelens member and to form a flange cavity around the lens member andextending to the buckle members, positioning the lens member within itsindividual mold support, positioning the buckle members within theirindividual mold supports at spaced positions around the lens member, andinjecting molding material into the flange cavity to form a flange thatovermolds to the lens member while at the same time overmolds to thebuckle members to form a respirator mask.
 2. The method of claim 1wherein the mold member is at least a two-piece mold that can be splitapart to release the respirator mask after molding the flange.
 3. Themethod of claim 1 wherein each buckle members is provided with anopening extending through the buckle member so that the molding materialcan flow through the opening to further secure each buckle member to theflange member.
 4. The method of claim 1 wherein the molding material isa thermoplastic rubber.
 5. (canceled)
 6. (canceled)
 7. (canceled) 8.(canceled)